Operation & Maintenance Manual

22
Operation & Maintenance Manual

description

Anivarya Pumps offers heavy duty gear pumps which is useful for pumping and transferring of heavy fuel oils. Generally made of iron Gear pumps are also available in cast steel, stainless steel.

Transcript of Operation & Maintenance Manual

  • Operation & Maintenance Manual

  • CUSTOMER APPLICATION DATA SHEET

    NAME:

    PO. NO:

    INVOICE NO:

    OPERATING DATA:

    LIQUID NAME:

    SP. GRAVITY:

    OPERATING PRESSURE

    SUCTION PRESSURE

    PUMP MODEL

    PUMP SPEED

    MOTOR RATING

    COUPLING TYPE

    BARE SHAFT PUMP

    DATE:

    DATE:

    VISCOSITY:

    CAPACITY

    PORT SIZE

    DIRECTION OF ROTATION

    BHP @ PUMP SHAFT

    MOTORISED PUMP SET

    OPERATING TEMPRETURE

    Authorised by :

  • INDEX

    Chapter Page No.

    1 General Description 1

    2 Installation

    2.1 Handling & Storage 2

    2.2 System Design & Installation 3

    3 Maintenance

    3.1 Cleaning in Place (CIP) 4

    3.2 Maintenance Schedule 5

    3.3 Disassembly 6

    3.4 Assembly 9

    4 Clearance Chart 13

    5 Trouble Shutting 14

    6 Part List 16

    7 Pumps Speed Selection Chart 17

    8 Test & Warrantee Certificate 18

  • GENERAL DESCRIPTION1

    1

    Lobe Pump

    Lifting hook

    Geared Motor

    Base Frame

    Bare Shaft Pump

    Pump with drive unit

  • Installation 2

    2

  • Installation 2

    Pump-1 Pump-2

    Suction Line

    Discharge Line

    3

  • Maintenance3

    4

  • Maintenance3

    5

  • Maintenance3

    6

  • Maintenance3

    7

  • Maintenance3

    8

  • Maintenance3

    9

  • Maintenance3

    10

  • Maintenance3

    11

    Filler Gauge

  • Maintenance3

    12

  • CLEARANCE TABLE4

    4.1 Lobe rotor clearance Table

    Pumps Model Pumps Model

    ALB 100 S/L

    ALB 150 S/L

    ALB 200 S/L

    ALB 250 S/L

    ALB 300 S/L

    ALB 400 S/L

    Front Front

    0.150

    0.150

    0.150

    0.200

    0.300

    0.350

    Rear Rear

    0.150

    0.150

    0.150

    0.200

    0.300

    0.350

    SideSide

    0.250

    0.250

    0.250

    0.250

    0.350

    0.400

    0

    Between Lobe @ 1800

    Between Lobe @ 180

    0.150

    0.150

    0.150

    0.200

    0.300

    0.350

    All dimensions are in mm

    4.2 Pump shaft Alignment :

    Parallel alignment: 0.2mm max

    Inclination alignments: 1 max

    0.2

    00

    mm

    Parralel alignment

    o

    1

    Angular alignment

    Cle

    aran

    ce b

    etwee

    n lo

    bes

    radia

    l cle

    ara

    nce

    Front Rear

    13

  • Probable Causes Solutions

    Incorrect direction of rotation Reverse motor.

    Pump not Primed.

    Insufficient NPSH available.

    Expel gas from suction line and pumping chamber

    and introduce fluid.

    Increase suction line diameter.

    Increase suction head.

    Simlify suction line configuration and resuce length.

    Reduce pump speed.

    Fluid vaporising in suction line. Increase suction line diameter.

    Increase suction head.

    Simplify suction line configuration and reduce length.

    Reduce pump speed.

    Air entering suction line. Remake pipework joints.

    Strainer or filter blocked. Service fittings.

    Fluid viscosity above rated figure. Increase fluid temperature.

    Decrease pump speed.

    Check seal face viscosity limitations.

    Fluid viscosity below rated figure. Decrease Fluid temperature.

    Increase pump speed.

    Fluid temp. above rated figure. Cool the pump casing.

    Reduce fluid temperature.

    Check seal face and elastomer temp. limitations.

    Fluid temp. below rated figure. Heat the pump casing.

    Increase fluid temperature.

    Unexpected solids in fuid. Clean the system.

    Fit strainer to suction line.

    Discharge pressure above rated

    figure

    Check for obstructions i.e. closed valve.

    Service system and change to prevent problem recurring.

    Simplify dicharge line to decrease pressure.

    Gland over-tightened Slacken and re-adjust gland packing.

    Gland under-tightened adjust gland packing.

    Se

    izu

    re

    Pa

    cke

    d g

    lan

    d le

    aka

    ge

    Me

    ch

    an

    ica

    l se

    al le

    aka

    ge

    Problem

    No flo

    w

    Under c

    apacity

    Irregula

    r d

    ischarge

    Low

    dis

    charge p

    ressure

    Pum

    p w

    ill not prim

    e

    Prim

    e lo

    st

    aft

    er s

    tartin

    g

    Pu

    mp

    sta

    lls w

    he

    n s

    tartin

    g

    Pu

    mp

    ove

    rh

    ea

    ts

    Moto

    r o

    verheats

    Exce

    ssiv

    e p

    ow

    er a

    bso

    rb

    ed

    No

    ise

    an

    d v

    ibra

    tio

    n

    Pu

    mp

    ele

    me

    nt

    we

    ar

    Pump speed above rated figure. Decrease pump speed.

    Pump speed below rated figure. Increase pump speed.

    Pump casing strained by

    pipework.

    Check alignment of pipes.

    Fit flexible pipes or expansion fittings.

    Support pipework.

    Flexible coupling misaligned. Check alignment and adjust mountings accrdingly.

    Insecure pump drive mountings. Fit lock washers to slack fasteners and re-tighten.

    Shaft bearing wear or failure. Refer to pump maker for advice and replacement parts.

    Insufficient gearcase lubrication. Refer to pump maker's instructions.

    Metal to metal contact of

    pumping element.

    Check rated and duty presures.

    Refer to pump maker.

    Worn pumping element. Fit new components.

    Suction lift too high. Lower pump or raise liquid level.

    Fluid pumped not compatible

    with materials used

    Use optional materials.

    No barrier system to prevent

    flow passing.

    Ensure discharge pipework higher than suction tank.

    Pump allowed to run dry. Ensure system operation prevents this.

    Fit single or double flushed mechanical seals.

    Fit flushed packed gland.

    Faulty motor. Check and replace motor bearings.

    Pumping element missing Fit pumping element.

    Trouble Shutting Trouble Shutting

    14

    5

  • 123

    4

    13

    12

    10

    11

    9

    8

    20

    22

    37

    39

    19

    24

    23

    25

    38

    5

    6

    7

    36

    35

    34

    33

    32

    31

    30

    28

    29

    27

    26

    41

    40

    16

    17

    15

    14

    18

    21

    15

  • Parts list

    16

    1. nut, front cover

    2. front cover

    3. O'Ring, Front cover

    4. stud

    5. hex cap nut

    6. O'Ring for lobe sealing

    7. lobe

    8. nut, pump casing

    9. washer

    10. dowel

    11. stud, pump casing

    12. shims

    13. pump casing

    14. bolt, clamp plate

    15. seal clamp plate

    16. m e c h a n i c a l s e a l ,

    stationary parts

    17. m e c h a n i c a l s e a l ,

    rotary parts

    18. seal spacer

    19. drain

    20. bolt, bearing cover

    21. Bearing cover

    22. oil seal bearing cover

    23. bolt, back cover

    24. back cover

    25. oil seal, back cover

    26. bolt, clamp plate

    27. clamp plate

    28. locking ring outer

    29. locking ring inner

    30. timing gear

    31. ring nut, bearing lock

    32. bearings, rear

    33. bearing spacer

    34. bearings, front

    35. stator shaft

    36. rotor shaft

    37. gear casing

    38. oil inlet

    39. oil indicator

    40. blot, base

    41. base

    6

  • Pump Speed Selection Chart 7

    * Speed of the pump should not exceed from the chart

    * Pump operating speed depends upon liquid viscosity

    pump speed chart

    liquid viscosity (cst)

    upto 1500

    1500 - 5000

    5000 - 15000

    15000 - 30000

    30000 - 50000

    50000 - 100000

    100000 - 200000

    pump operating speed (rpm)

    1000

    750

    500

    380

    300

    200

    150

    17

  • TEST & WARRANTEE CERTIFICATE8

    18

    TEST RESULT

    PUMP NO :

    RATED CAPACITY

    PRESSURE

    CAPACITY

    POWER

    CONSUMED

    SPEED

    MODEL :

    RATED PRESSURE

    TEST DURATION :

    TEST

    TEMP.

    TEST

    MEDIA

    KGF/CM2

    LPM

    HP

    RPM

    Signature :

    QC DEPARTMENT

  • Other Products

    ANI ENGINEERS

    Plot no. 2716, G.I.D.C. Estate, Phase-IV, Wadhwan 363 035. Surendranagar (Guj.) India.

    Ph.: +91-2752-241479, Fax : +91-2752-242479

    Web : www.anivaryapumps.com, E-mail : [email protected]

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